The Job
Norfolk Southern required the construction of a new passenger platform in Virginia’s New River Valley. The project involved placing 12,000 cubic yards of backfill behind Gravix precast wall systems to create the necessary elevation for the rail facility. Because the site sat atop compressible soils, the design necessitated a lightweight fill solution to minimize settlement and ensure the long-term stability of the new infrastructure. CJGeo worked alongside Norfolk Southern and Anderzack-Pitzen Construction, Inc. to execute this large-scale bulk filling operation.
The Challenge
The primary technical hurdle involved raising grades significantly without overloading the underlying soil strata. The original project specifications called for Foam Glass Aggregate (FGA). However, using a granular lightweight fill presented logistical and schedule risks. The contractor needed a solution that allowed for faster placement and the ability to pour in higher lifts behind the Gravix walls to stay ahead of the construction timeline. Additionally, the project required high-volume production, with placement targets exceeding 200 cubic yards per pour, across two distinct phases during the fall and winter months.
The Solution
CJGeo provided a Value Engineering (VE) alternative by replacing the FGA with CJFill-UL 25 lightweight cellular concrete. This ultra-lightweight material significantly reduced the axial load on the compressible soils while providing superior lateral stability behind the Gravix walls. By using CJFill-UL, the crew achieved placement rates of over 200 cubic yards per shift, which accelerated the overall project schedule compared to traditional aggregate methods. CJGeo managed the work in two mobilizations to accommodate the phased installation of the wall system. The project concluded on time and within budget, providing a stable, low-density foundation for the new passenger platform.
Speak With An Expert
Are you facing settlement challenges on compressible soils or looking for a faster alternative to traditional lightweight aggregates? CJGeo specializes in high-production cellular concrete for rail and transportation infrastructure. Contact us today to discuss how our lightweight fill solutions can optimize your next project.
